Insulation
The insulation provided on each conductor of a cable by mainly PVC (Poly Vinyl Chloride), XLPE
(Crosslinked Polyethylene), RUBBER (Various Types of Rubber). The insulating material is based on
operating temperature.
Insulation
Plastic Insulation
Polyvinyl chloride (PVC)
PVC is resistant to moisture, flame and abrasion and can be used in lots of environments: acids, solvents
and ozone. PVC-insulated cables also have no taste or odor, therefore they are not toxic. The allowable
temperature range for this material is from -55°C to 105°C.
Semi-rigid (SR) PVC
SR-PVC has similar resistance characteristics to PVC insulation, but this one works better when
maximum resistance to abrasion is the priority.
Plenum PVC
Plenum PVC is also made of polyvinyl chloride but is best suited for installations in indoor areas with air
circulation, like raised floors or dropped ceilings.
Insulation
Polyethylene (PE)
PE is an inflexible material used when high-speed transmission and low capacitance are needed. PE is
also a go-to cable insulation option for coaxial wires. The material is resistant to soldering, cracking and
solvents, with an operating temperature ranging from -65°C to 80°C. XLPE (cross-linked polyethylene)
insulation is a commonly used subtype of PE insulation.
Polypropylene (PP)
PP has similar characteristics to PE but is mostly used in indoor environments. The allowable
temperature range for this insulation material is 30°C-80°C.
Polyurethane (PUR)
PUR is a flexible material mostly used for electrical cables targeted for low-temperature and marine
environments. It is resistant to moisture, chemicals and abrasion, and its operating temperature ranges
from -60°C to 90°C.
Insulation
Rubber Insulation
Thermoplastic rubber (TPR)
TPR is resistant to heat and harsh weather conditions and is the best fit for when a high processing
speed is required.
Neoprene (Polychloroprene)
Neoprene is resistant to abrasion, oils and solvents. This insulation material makes an electrical cable
long-lasting.
Ethylene propylene rubber (EPR)
EPR is widely used for high-voltage cables - it is flexible and resistant to most irritants. The allowable
temperature range for EPR cable insulation is from -50°C to 160°C.
Ethylene propylene diene monomer (EPDM)
EPDM is resistant to harsh weather conditions, heat and abrasion while also being a strong dielectric and
flexible. Its operating temperature ranges from -55°C- to 50°C.
Beading (Inner Sheath)
This portion of the cable is also known as the inner sheath. Mostly it is used in Multi-core cables. It
works as a binder for insulated conductors together in multi-core power cables and provides bedding to
armor. This portion of the cable is mainly made of PVC, RUBBER.
Armoring
There are mainly G.I. WIRE ARMOURING, G.I. STEEL STRIP armoring. I done by placing G.I. WIRES, GI, or
STEEL STRIPS one by one on inner sheath. Armoring is a process that is done mainly for providing an
earthing shield to the current-carrying conductors as well as it is also used for earthing purposes of the
cable for safety and Provides extra mechanical protection and strength to cables
When there is any insulation failure in the conductor, the fault current gets enough paths to flow
through the armor if it is properly earthed.
Wire-Braid Armoured Cable
Wire braid armor is also known as basket-weave armour. It is used when light and flexible protection is
needed.
Wire braid is constructed much like a fibrous braid. The metal is knitted directly over the cable as the
outer covering.
Generally, the braid is made of galvanized steel, copper, bronze, or aluminium.
Armouring
Steel/Aluminium Wire Armoured Cable
They are generally abbreviated as SWA cable (Steel Wire Armour).
SWA Cables is suitable for high drop areas and can withstand external mechanical forces and extensive
tension.
Cables with multiple cores use Steel wire armour. It withstands high pull loads.
Armouring
Steel Tape Armoured Cable
They are often abbreviated as STA (Steel Tape armour).
STA Cables are suitable for buried laying and can withstand external mechanical forces but cannot
withstand large tensile forces.
Armouring
Aluminium Wire Armoured Cable
The cables are generally abbreviated as AWA. Because of the non-
magnetic nature of Aluminium, there would not be any induced currents in
the armour due to the currents flowing in the main conductor.
Aluminium Wire armour is used in single-core cable.
Outer Sheath
This is the outermost cover of the cable normally made of PVC (Poly Viny Chloride), RUBBER (Various
Types of Rubber), and often the same material as the bedding. It is provided over the armor for overall
mechanical, weather, chemical, and electrical protection. The outer sheath is the protection offered to
the cable not much electrically but more mechanically.
Insulation Material
PVC TYPE A
Maximum Operating Temperature
75°C
PVC TYPE B
85°C
PVC TYPE C
XLPE
RUBBER - EPR IE-1
85°C
90°C
90°C
RUBBER - EPR IE-2, EPR IE-3, EPR IE-4, SILICON IE-
150°C
Material Advantages
PVC
Cheap, Durable, Widely available
Lowest dielectric losses,
PE
High initial dielectric
strength
XLPE
Disadvantages
Highest dielectric losses, Melts
at high temperatures, Contains halogens
Highly sensitive to water treeing, Material breaks down at high temperatures
Max Operating
Temperature
70°C for general-
purpose 85°C for heat-resisting
purpose
Does not melt but thermal
Low dielectric losses, Improved material properties at high
expansion occurs, Medium
sensitivity to water treeing
90°C
(although some XLPE
temperatures
polymers are water-tree
resistant)
EPR
Increased flexibility,
Reduced thermal
expansion (relative to
XLPE), Low sensitivity to water treeing
Low-Medium dielectric
Medium-High dielectric losses,
Requires inorganic
filler/additive
High weight, High cost,
Requires hydraulic
90°C
Paper/
Oil
losses, Not harmed by DC testing, Known
pressure/pumps for insulating fluid, Difficult to repair,
70°C
history of reliability
Degrades with moisture